During production, over-filling or under-filling errors can occur for various reasons: operator mistakes, incorrect system settings, filling system blockages, or equipment maintenance requirements. Identifying and addressing these issues promptly helps avoid product waste, rework requirements, and rejected or returned products, which all impact profit margins.
Manufacturers can reduce product giveaway from over-filled packages and prevent the sale of under-filled products by conducting a simple quality check to inspect packaged products for correct fill levels. This control measure can help avoid customer dissatisfaction and costly fines associated with non-compliance with consumer regulations.
Manufacturers can perform in-line fill level control checks without slowing down production speeds by installing a fill level inspection system on the production line. Product inspection systems from METTLER TOLEDO can quickly identify and remove under- or over-filled products and provide real-time feedback to filling equipment, reducing the need for product rework and production downtime.
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Methods for Fill Level Inspection
Fill level inspection equipment can refer to any number of technologies. The type of inspection equipment depends on the product packaging and characteristics.
Checkweighing for Fill Level Control
In-line checkweighing is the simplest and most common method used by manufacturers for fill level control. Dynamic checkweighers weigh items as they move along the production line. They make use of a load cell to verify the measured weight against the expected weight. Products that are lighter or heavier than expected are removed from the production line using an automatic reject device. The type of reject device varies depending on the type of product being inspected.
X-ray inspection systems are commonly used to detect physical contamination, but they can also be used to determine the fill level of a product. The system generates an x-ray image of the contents within a container to measure the amount of product present. If the product appears over-filled or under-filled, it can be removed from the production line using a reject device.
It should be noted that x-ray fill level inspection may not be the best method to use for product contents that can settle or shift significantly while traveling on the production line.
Vision inspection uses a camera to take a picture of the container to visually verify the fill level. Vision systems can also be used to inspect the outside of the package for label verification and print inspection. This method of fill level inspection is only possible when the packaging is not completely opaque.
Similar to x-ray inspection, using vision systems for fill level control may not be as reliable for products with contents that can shift or settle significantly.
All dynamic checkweighing systems from METTLER TOLEDO are able to send digital feedback to filling equipment. This enables real-time adjustments to filling machine settings, minimizing the need for product rework. If a more serious problem arises with the filling equipment, the systems can report the issue and stop production automatically, further reducing product waste.
More information about our fill level inspection system capabilities can be found on our Optimizing Filling Processes know-how page.
Choosing the most appropriate solution to meet your fill level inspection equipment requirements is easier when you partner with a product inspection equipment provider who can provide options such as:
Local service support to achieve optimal equipment performance
Customized and combination solutions to handle a variety of quality inspection needs
METTLER TOLEDO has decades of experience in designing and manufacturing a range of standard and customized in-line quality inspection solutions. Our fill level inspection solutions are designed to make it easier to control accurate fill levels of your products, resulting in less product waste and protecting against fines and unhappy consumers.
We provide inspection solutions for a range of industries and product types, such as:
ProdX™ Data Management Software provides centralized monitoring of product inspection systems - including fill level trends. This allows for fast and easy analysis of filler efficiency, remote system setup, and product changeover capabilities. Paperless recording of test routines allow for audit-proof documentation and verification of system performance. Read more
Professional installation, configuration and verification allow systems to function at their best from the start. Training services bring employees up-to-speed on proper system operation, reducing the risk of operator error. Service plans and regular maintenance visits keep equipment operating at top efficiency for the life of the system. Spare part kits enable fast responses to unexpected downtime and support a preventative maintenance program. Read more
We offer free product test reports, live online demonstrations and provide access to rental systems to help you simplify and support the decision-making process. Whether you want to quickly scale up production, adapt to variable demand or test equipment before making the investment, we have a solution that can help. Read more
This eBrochure discusses the potential of combination inspection systems. It provides an overview of...
FAQs
How can I control fill levels in manufacturing?
Fill level control is accomplished by adding fill level inspection equipment to the production line. Ideally, it should be placed after or integrated into the filler itself.
There are several types of equipment available for fill level inspection, including checkweighers, x-ray inspection systems, and vision inspection systems.
With the help of fill level inspection equipment, each product can be verified for correct fill level, with over- or under-filled packages automatically removed from the production line.
How can I monitor the performance of fill level inspection equipment?
Fill level inspection equipment tracks real-time data to monitor filling equipment performance and product fill levels. This data enables automatic adjustments to be made to the filling equipment to correct any filling issues during production. This means that if a filler dispenses too much or too little product, the system signals the filler to automatically adjust and correct the error without stopping production.
What are the effects of over-filling and under-filling in canned foods?
Over-filling canned foods can be costly as even minor errors can accumulate quickly. Under-filling canned foods can also be expensive as it can lead to dissatisfied customers and damage to your brand reputation. Additionally, it is crucial for canned foods to contain the specified amount of product as mandated by government regulations. If under-filled products are released and detected, you may have to recall them and pay substantial fines.
With the help of an in-line checkweighing solution, it is easy to verify that cans have been properly filled. For more information on the METTLER TOLEDO checkweighing portfolio, please follow the link below.
